High performance silicon based thermal coating compositions

ABSTRACT

The present disclosure provides silicon-based coating compositions, comprising 8% to 30% (w/w of the total composition) polysilazane, 8% to 22% (w/w of the total composition) polysiloxane, and 30% to 45% (w/w of the total composition) high temperature silicone-based resin. The composition after curing is a thermal barrier coating that can withstand temperature over 1600° F. in accordance with ASTM E1530 test standards for heat stability, having a thickness ranging between about 0.4 mil and about 1.5 mil and a hardness ranging between about 4 H and about 9 H. Also provided are methods for applying these coatings.

CROSS REFERENCE

This application is a continuation of U.S. patent application Ser. No.13/891,438, filed on May 10, 2013, and titled “High Performance SiliconBased Thermal Coating Compositions,” which claims the priority benefitof U.S. provisional application 61/645,487, filed on May 10, 2012, andthe teachings of which are incorporated herein by reference in theirentities for all purposes.

TECHNICAL FIELD

The present disclosure relates to silicon-based coating compositionsformed from silazane, siloxane, and silane, and optionally, organicsolvents and additives. The resultant composition can be used forcoating a surface to form coatings having desired features includinghigh temperature and heat resistance, and good hardness. Such coatingsare useful in a wide range of applications.

BACKGROUND

Chemical structure and conformation of the polymer are among the manyfactors that influence the type of coating for a particular application.However, the commercial availability of many useful polymers oftenlimits the applications. For example, for a long time polysilazanes havebeen synthesized and characterized, which acknowledges that such apolymer could be useful in a variety of applications. Currently,however, few products have been developed into a marketable commodity.Additionally, there are cost limitations that prohibit use in somecases.

There is a great need for an improved silicon-based coating for use in awide range of applications. Such coating would be curable at ambienttemperature conditions without requiring an added catalyst or activatorfor rapid curing, thin but durable, protective and heat-stable,displaying excellent hardness, remaining intact even when the substrateis deformed. In addition, coatings that are customizable in terms ofcoating color, appearance, feel, and glossiness are desirable. Further,coatings being UV resistant, microbial releasable, easy to clean andmaintain, and corrosion resistant are also in great need for their widerange of uses.

Therefore, given the limitations of the prior art, it is desirable tohave a coating composition that has the physical and chemicalcharacteristics of the polymer substrates, and results in coatingspossessing a number of desirable properties along with superior heat andhigh temperature resistance than the existing silicone-based paint orcoating, such as Thurmalox® products, which withstand temperature up to1200° F.

SUMMARY

The present disclosure relates to silicon-based coating compositionsapplicable to a wide range of surfaces, which composition is formed froma mixture of constituents comprising appropriate portions of polymerizedsilazane resin, polymerized siloxane resin, polymerized silane resin,high temperature silicone-based resins, and optionally, portions oforganic solvent and additives. The resultant coating has a thickness of0.4 to 1.5 mil (1 mil=0.001 inches or 25.4 μm), a hardness of 4-9 H (H,hardness; using ASTM D3363 test standards), and a continuous temperatureendurance above 1600° F. Such combinations having specific portions ofsilicon-based polymers provide coatings having advantageous propertiesincluding, but not limited to, clear, thin, light, slick, hard, highheat and high temperature resistant, ice build-up resistant, UVresistant, chemical resistant, and microbial resistant. In addition, thecompositions as provided herein allow for a lower concentration ofpolymerized silazane resin and thus reduce the cost, simplify mixingsteps and processes, and decrease in odor of the finished coatingproducts.

Generally, the silicon-based coating composition, which after curing, isa thermal barrier coat composition that can withstand continuoustemperature over 1600° F., having a thickness ranging between about 0.4mil and about 1.5 mil and a hardness ranging between about 4 H and about9 H. The general composition is formed from a mixture of constituentscomprising: between about 1% (w/w) and about 80% (w/w) silazane, betweenabout 1% (w/w) and about 30% (w/w) siloxane, between about 1% (w/w) andabout 30% (w/w) silane, and between about 1% (w/w) and about 90% (w/w)high temperature silicone based resin.

One embodiment relates to a silicon based coating composition comprisingbetween about 1% and about 99% (w/w), by weight of the totalcomposition, of a first mixture containing: 60% to 70% (w/w) silazane;12% to 22% (w/w) siloxane; 12% to 22% (w/w) silane, by weight of thefirst mixture; and 1% to 99% (w/w), by weight of the total composition,of a second mixture containing: 77% to 87% (w/w) high temperaturesilicone based resin; 7% to 17% (w/w) organic solvent; 1% to 5% (w/w)ceramic microsphere; and 1% to 5% (w/w) corrosion inhibitor, by weightof the second mixture.

A second embodiment relates to a silicon based coating compositioncomprising 45% to 55% (w/w), by weight of the total composition, of afirst mixture containing: 60% to 70% (w/w) silazane; 12% to 22% (w/w)siloxane; 12% to 22% (w/w) silane, by weight of the first mixture; and45% to 55%, by weight of the total composition, of a second mixturecontaining: 77% to 87% (w/w) high temperature silicone based resin; 7%to 17% (w/w) organic solvent; 1% to 5% (w/w) ceramic microsphere; and 1%to 5% (w/w) corrosion inhibitor, by weight of the second mixture.

A third embodiment relates to a silicon based coating compositioncomprising 85% to 95% (w/w), by weight of the total composition, of afirst mixture containing: 60% to 70% (w/w) silazane; 12% to 22% (w/w)siloxane; 12% to 22% (w/w) silane, by weight of the first mixture; and5% to 15% of a second mixture containing: 77% to 87% (w/w) hightemperature silicone based resin; 7% to 17% (w/w) organic solvent; 1% to5% (w/w) ceramic microsphere; and 1% to 5% (w/w) corrosion inhibitor, byweight of the second mixture.

A fourth embodiment relates to a silicon based coating compositioncomprising 5% to 15% (w/w), by weight of the total composition, of afirst mixture containing: 60% to 70% (w/w) silazane; 12% to 22% (w/w)siloxane; 12% to 22% (w/w) silane, by weight of the first mixture; and85% to 95% (w/w), by weight of the total composition, of a secondmixture containing: 77% to 87% (w/w) high temperature silicone basedresin; 7% to 17% (w/w) organic solvent; 1% to 5% (w/w) ceramicmicrosphere; and 1% to 5% (w/w) corrosion inhibitor, by weight of thesecond mixture.

A fifth embodiment relates a silicon based coating composition,comprising 23% to 33% (w/w), by weight of the total composition, of afirst mixture containing: 60% to 70% (w/w) silazane, 12% to 22% (w/w)siloxane, 12% to 22% (w/w) silane, by weight of the first mixture; 46%to 66% (w/w), by weight of the total composition, of a second mixturecontaining: 77% to 87% (w/w) high temperature silicone based resin, 7%to 17% (w/w) organic solvent, 1% to 5% (w/w) ceramic microsphere, and 1%to 5% (w/w) corrosion inhibitor; and 1% to 30% (w/w) mica pigmentsselected from the group consisting of mica group minerals, silica groupminerals, and any combination thereof, by weight of the second mixture.

In addition, the present disclosure further provides a method of coatinga surface, the method comprising mixing a mixture of constituentscomprising: mixing a mixture of constituents to form a silicon basedcoating composition comprising: from about 1% (w/w) to about 80% (w/w)silazane, from about 1% (w/w) to about 30% (w/w) siloxane, from about 1%(w/w) to about 30% (w/w) silane, and from about 1% (w/w) to about 90%(w/w) high temperature silicone based resin; coating the mixture onto asurface; and curing the coating ambiently with or without additionalheat.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of skill in theart to which this disclosure belongs at the time of filing. Ifspecifically defined, then the definition provided herein takesprecedent over any dictionary or extrinsic definition. Further, unlessotherwise required by context, singular terms shall include pluralities,and plural terms shall include the singular. Herein, the use of “or”means “and/or” unless stated otherwise. All patents and publicationsreferred to herein are incorporated by reference.

DETAILED DESCRIPTION

Silicon based coating compositions formed from certain silicon-basedpolymers to make high performance coatings with desirable propertiesincluding high temperature and high heat resistance. As such, the topcoatings provided by these compositions are clear, thin, hard, slick,having shortened curing process, and with resistance or high enduranceto adverse conditions including, but not limited to, drag, scrub,friction, heat, moisture, high temperature, low temperature, UVexposure, ice build-up, microbial growth, corrosion, and the like. Thecompositions comprise polymerized silane and either or both ofpolymerized silazane and siloxane, and may further comprise one or morenon-reactive organic solvents, and/or one or more additives for curingor for finishing, each of which in a proportion as designed herein toachieve certain properties. In addition, the present disclosure is basedin part on the finding that compositions comprising a combination ofvarious silicon-based polymers results in product providing betterprotections to exterior surfaces and underlying finish, and/or substratein a wide range of applications.

The silicon-based coating compositions include polymerized silazane.“Silazane” and “polysilazane”, as appearing in the specification andclaims are generic terms intended to include compounds which contain oneor more silicon-nitrogen bonds in which the nitrogen atom is bonded toat least two silicon atoms and may or may not contain cyclic units.Therefore, the terms “polysilazane” and “silazane polymer” includemonomers, oligomers, cyclic, polycyclic, linear polymers or resinouspolymers having at least one Si—N group in the compound, or havingrepeating units of H₂Si—NH, that is, [H₂Si—NH]_(n), with “n” greaterthan 1. The chemical structure for polysilazane is shown below.

By “oligomer” is meant any molecule or chemical compound which comprisesseveral repeat units, generally from about 2 to 10 repeat units. Asimple example of silazane oligomer is disilazane H₃Si—NH—SiH₃.“Polymer”, as used herein, means a molecule or compound which comprisesa large number of repeat units, generally greater than about 10 repeatunits. The oligomeric or polymeric silazanes may be amorphous orcrystalline in nature. Polysilazane or a mixture of polysilazanes knownin the art or commercially available include such products generallyknown among persons skilled in the art as: silazanes, disilazanes,polysilazanes, ureasilazanes, polyureasilazanes, aminosilanes,organosilazanes, organopolysilazanes, inorganic polysilazanes, andothers employing liquid anhydrous ammonia in their production. One groupof polysilazane, [R₁R₂Si—NH]_(n), is isoelectronic with and closerelatives to polysiloxane [R₁R₂Si—O]_(n). A polysilazane with thegeneral formula (CH₃)₃Si—NH—[(CH₃)₂Si—NH]_(n)—Si(CH₃)₃ is designated aspolydimethylsilazane.

The making of polysilazane using ammonolysis procedure was disclosed inU.S. Pat. No. 6,329,487. In addition, polysilazane is also commerciallyavailable. For example, polysilazane (>99%) in tert-butyl acetatesolvent manufactured by KiON Defense Technologies, Inc. (HuntingdonValley, Pa.) as KDT Ambient Cure Coating Resin (KDT HTA® 1500) issupplied as a 100% solids liquid of low viscosity. KDT HTA® 1500 maycomprise less than 5% cyclosilazane, a cyclic form of polysilazane.Similar product is also available from other manufacturers including AZElectric Materials (Branchburg, N.J.).

Polysilazane comprises between about 0% and about 80% (w/w) of the totalformula weight of silicon-based coating compositions. In one embodiment,the silicon-based coating composition does not contain polysilazane. Insome embodiments, polysilazane (A-Resin, as designated herein) comprisesabout 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%,15%, 10%, 5%, 4%, 3%, 2%, 1% (w/w), or any range thereof, of thesilicon-based coating composition. For example, the amount ofpolysilazane present in the silicon based coating composition may rangefrom between about 5% to about 10%, between about 8% to about 30%,between about 25% to about 40%, between about 35% to about 55%, betweenabout 55% to about 70%, between about 60% to about 80%, (w/w) of thetotal composition, and ranges from between about 5% to about 7%, betweenabout 7% to about 9%, between about 18% to about 20%, between about 34%to about 37%, between about 38% to about 42%, between about 45% to about55%, between about 64% to about 68%, (w/w) of the total composition. Inan exemplary embodiment, the amount of polysilazane present in thecomposition is 6% (w/w) of the total composition. In another exemplaryembodiment, the amount of polysilazane present in the composition is 8%(w/w) of the total composition. In another exemplary embodiment, theamount of polysilazane present in the composition is 19% (w/w) of thetotal composition. In yet another exemplary embodiment, the amount ofpolysilazane present in the composition is 28% (w/w) of the totalcomposition. In still another exemplary embodiment, the amount ofpolysilazane present in the composition is 36% (w/w) of the totalcomposition. In yet another exemplary embodiment, the amount ofpolysilazane present in the composition is 40% (w/w) of the totalcomposition. In still another exemplary embodiment, the amount ofpolysilazane present in the composition is 50% (w/w) of the totalcomposition. In still another exemplary embodiment, the amount ofpolysilazane present in the composition is 66% (w/w) of the totalcomposition.

The silicon-based coating compositions also include polymerizedsiloxane. A siloxane is a chemical compound having branched orunbranched backbones consisting of alternating silicon and oxygen atoms—Si—O—Si—O— with side chains R attached to the silicon atoms (R₁R₂SiO),where R is a hydrogen atom or a hydrocarbon group. Polymerizedsiloxanes, including oligomeric and polymeric siloxane units, withorganic side chains (R≠H) are commonly known as polysiloxanes, or[SiOR₁R₂]_(n), with “n” greater than 1. The chemical structure forpolysiloxanes is shown below.

In addition to hydrogen, R₁ and R₂ of polysiloxane are independentlyselected from the group consisting of an alkyl, an alkenyl, acycloalkyl, an alkylamino, aryl, aralkyl, or alkylsilyl. Thus, R₁ and R₂can be such groups as methyl, ethyl, propyl, butyl, octyl, decyl, vinyl,allyl, butenyl, octenyl, decenyl, tetradecyl, hexadecyl, eicosyl,tetracosyl, cyclohexyl, methylcyclohexyl, methylamino, ethylamino,phenyl, tolyl, xylyl, naphthyl, benzyl, methylsilyl, ethylsilyl,propylsilyl, butylsilyl, octylsilyl, or decylsilyl. These alkyl,alkenyl, cycloalkyl, aryl, alkyl amino, aralkyl and alkylsilyl groupsmay each optionally be substituted by one or more substituents whichcontain heteroatoms, such as halides, like chlorine, bromine and iodine;alkoxy groups, like ethoxy, and also aryl groups, such as acetyl andpropionyl. Organic side groups can be used to link two or more of these—Si—O— backbones together. By varying the —Si—O— chain lengths, sidegroups, and crosslinking, polysiloxanes can vary in consistency fromliquid to gel to rubber to hard plastic. Representative examples ofpolysiloxane are [SiO(CH₃)₂]_(n) (polydimethylsiloxane, PDMS) and[SiO(C₆H₅)₂]_(n) (polydiphenylsiloxane). In an embodiment, thesilicon-based coating composition comprises polydimethylsiloxane. Thechemical structure for polydimethylsiloxane is shown below.

Octamethyltrisiloxane, [(CH₃)₃SiO]₂Si(CH₃)₂, is a linear siloxane in thepolydimethylsiloxane family, with the INCI name as Trisiloxane. Thechemical structure for Octamethyltrisiloxane is shown below.

Other methylated siloxanes include, but are not limited to:hexamethyldisiloxane, cyclotetrasiloxane, octamethylcyclotetrasiloxane,decamethyltetrasiloxane, decamethylcyclopentasiloxane. The method ofproducing high molecular weight polysiloxane product was disclosed inUS. App. Pub. 20090253884. In addition, polysiloxane is alsocommercially available. As one example, polysiloxane, specifically,polydimethylsiloxane, is supplied in isopropyl acetate solvent byGenesee Polymers Corp. (Burton, Mich.), and it is sold as DimethylSilicone Fluids G-10 product. Polysiloxane (B-Resin, as designatedherein) comprises between about 0% and about 30% (w/w) of the totalformula weight of silicon-based coating compositions. In one embodiment,the silicon-based coating composition does not contain polysiloxane. Insome embodiments, polysiloxane comprises about 30%, 27%, 25%, 23%, 20%,17%, 15%, 13%, 10%, 7%, 5%, 4%, 3%, 2%, 1% (w/w), or any range thereof,of the silicon-based coating composition. For example, the amount ofpolysiloxane present in the silicon based coating composition may rangefrom between about 5% to about 10%, between about 8% to about 22%,between about 20% to about 30%, (w/w) of the total composition, andranges from between about 7% to about 9%, between about 12% to about20%, between about 22% to about 28%, (w/w) of the total composition. Inan exemplary embodiment, the amount of polysiloxane present in thecomposition is about 8% (w/w) of the total composition. In anotherexemplary embodiment, the amount of polysiloxane present in thecomposition is 15% (w/w) of the total composition. In another exemplaryembodiment, the amount of polysiloxane present in the composition is 25%(w/w) of the total composition.

The silicon-based coating compositions may further include polymerizedsilane. Silanes are compounds which contain one or more silicon-siliconbonds. Polysilanes [R₁R₂Si—R₁R₂Si]_(n) are a large family of inorganicpolymers. The number of repeating units, “n”, plays a role indetermining the molecular weight and viscosity of the composition Likein polysiloxane, R₁ and R₂ are independently selected from the groupconsisting of a hydrogen, an alkyl, an alkenyl, a cycloalkyl, analkylamino, aryl, aralkyl, or alkylsilyl. Thus, R₁ and R₂ can be suchgroups as methyl, ethyl, propyl, butyl, octyl, decyl, vinyl, allyl,butenyl, octenyl, decenyl, tetradecyl, hexadecyl, eicosyl, tetracosyl,cyclohexyl, methylcyclohexyl, methylamino, ethylamino, phenyl, tolyl,xylyl, naphthyl, benzyl, methylsilyl, ethylsilyl, propylsilyl,butylsilyl, octylsilyl, or decylsilyl. A polymer with the generalformula —[(CH₃)₂Si—(CH₃)₂Si]—_(n), is designated as polydimethylsilane.The chemical structure of polydimethylsilane is shown below.

High molecular weight polysilane product with a narrow molecular weightdistribution may be obtained by the process of U.S. Pat. No. 5,599,892.Polysilane is also available as a resin system supplied in amyl acetateblend from Kadko, Inc. (Beech Grove, Ind.), and it is sold as a KADKLADR2X3™ product. Polysilane (C-Resin, as designated herein) comprisesbetween about 0% and about 80% (w/w) of the total formula weight ofsilicon-based coating compositions. In one embodiment, the silicon-basedcoating composition does not contain polysilane. In some embodiments,polysilane comprises about 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%,35%, 30%, 27%, 25%, 23%, 20%, 17%, 15%, 13%, 10%, 7%, 5%, 4%, 3%, 2%, 1%(w/w), or any range thereof, of the silicon-based coating composition.For example, the amount of polysilane present in the silicon-basedcoating composition may range from between about 60% to about 80%,between about 50% to about 65%, between about 30% to about 55%, betweenabout 15% to about 35%, between about 8% to about 20%, (w/w) of thetotal composition, and ranges from between about 65% to about 78%,between about 60% to about 75%, between about 25% to about 32%, betweenabout 22% to about 28%, between about 8% to about 12%, (w/w) of thetotal composition. In an exemplary embodiment, the amount of polysilanepresent in the composition is about 73% (w/w) of the total composition.In another exemplary embodiment, the amount of polysilane present in thecomposition is 67% (w/w) of the total composition. In another exemplaryembodiment, the amount of polysilane present in the composition is 28%(w/w) of the total composition. In yet another exemplary embodiment, theamount of polysilane present in the composition is 25% (w/w) of thetotal composition. In yet another exemplary embodiment, the amount ofpolysilane present in the composition is 17% (w/w) of the totalcomposition. In still another exemplary embodiment, the amount ofpolysilane present in the composition is 10% (w/w) of the totalcomposition.

The silicon-based coating compositions may further include hightemperature silicone-based resin. While silicone resins with long alkylchains do not withstand high temperatures very well, silicon resins thatare characterized by a branched framework of silicon atoms connectedwith each other by oxygen atoms possess special properties such as highheat and weathering resistance. Further, heat resistance can be markedlyraised if the alkyl chains are replaced by phenyl or methyl groups,which results in extraordinarily heat resistant resins stable up to 660°F. High temperature silicon-based resins resistant to a range oftemperatures are commercially available. For example, Hi-Temp™ coatings(Ti-Temp Coatings technology, Boxborough, Mass.), SILRES® silicone resin(Wacker Chemie AG, München, Germany), and Thurmalox® Resin (DampneyCompany, Inc., Everett, Mass.) are some of the heat resistant products.Similar product is also available from other manufacturers.

High temperature silicone-based resin comprises between about 1% andabout 90% (w/w) of the total formula weight of silicon-based coatingcompositions. In one embodiment, the silicon-based coating compositioncontains high temperature silicon-based resin. In some embodiments, hightemperature silicon-based resin comprises about 90%, 85%, 80%, 75%, 70%,65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 4%, 3%,2%, 1% (w/w), or any range thereof, of the silicon-based coatingcomposition. For example, the amount of high temperature silicon basedresin, present in the silicon based coating composition may range frombetween about 5% to about 10%, between about 8% to about 30%, betweenabout 25% to about 40%, between about 35% to about 55%, between about50% to about 70%, between about 60% to about 80%, between about 75% toabout 90% (w/w) of the total composition, and ranges from between about5% to about 15%, between about 15% to about 30%, between about 30% toabout 45%, between about 45% to about 60%, between about 60% to about80%, between about 80% to about 90%, (w/w) of the total composition. Inan exemplary embodiment, the amount of high temperature silicon-basedresin present in the composition is about 74% (w/w) of the totalcomposition. In another exemplary embodiment, the amount of hightemperature silicon-based resin present in the composition is about 55%(w/w) of the total composition. In another exemplary embodiment, theamount of high temperature silicon-based resin present in thecomposition is about 41% (w/w) of the total composition. In yet anotherexemplary embodiment, the amount of high temperature silicon-based resinpresent in the composition is about 27% (w/w) of the total composition.In still another exemplary embodiment, the amount of high temperaturesilicon-based resin present in the composition is about 8% (w/w) of thetotal composition.

The silicon-based coating compositions may additionally include one ormore organic solvents. Generally, the organic solvent is defined as acarbon-containing chemical that is capable of dissolving a solid,liquid, or a gas. Although one skilled in the art will appreciate that awide variety of solvents may be incorporated, suitable solvents arethose that contain no water and no reactive groups such as hydroxyl oramine groups. These solvents include, but not limited to, for example,aromatic hydrocarbons; aliphatic hydrocarbons, such as, hexane, heptane,benzene, toluene, branched-chain alkanes (isoparaffins); halogenatedhydrocarbons; esters, such as methyl acetate, n-butyl acetate,tert-butyl acetate, isobutyl acetate, sec-butyl acetate, ethyl acetate,amyl acetate, pentyl acetate, 2-methyl butyl acetate, isoamyl acetate,n-propyl acetate, isopropyl acetate, ethylhexyl acetate; ketones, suchas acetone or methyl ethyl ketone; ethers, such as tetrahydrofuran,dibutyl ether; and mono- and polyalkylene glycol dialkyl ethers (glymes)or mixtures of these solvents may be used. In an embodiment, the organicsolvent comprises n-butyl acetate. In another embodiment, the organicsolvent comprises tert-butyl acetate. In yet another embodiment, theorganic solvent comprises isoparaffins.

In addition, the organic solvent generally comprises between about 0% toabout 70% (w/w) of the silicon-based coating composition. In someembodiments, the organic solvent comprises about 70%, about 65%, about60%, about 55%, about 50%, about 45%, about 40%, about 35%, about 30%,about 25%, about 20%, about 15%, about 10%, about 5%, or about 0% (w/w)of the total composition. For example, the amount of organic solventpresent in the silicon-based coating composition ranges from betweenabout 0% to about 35% (w/w) of the composition. In another embodiment,the amount of organic solvent in the silicon-based coating compositionranges from between about 10% to about 45% (w/w) of the totalcomposition. In another embodiment, the amount of organic solvent in thesilicon-based coating composition ranges from between about 10% to about35% (w/w) of the total composition. In an additional embodiment, theamount of organic solvent in the silicon-based coating compositionranges from between about 20% to 55% (w/w) of the total composition. Instill another embodiment, the amount of organic solvent in thesilicon-based coating composition ranges from between about 25% to 45%(w/w).

The silicon based coating compositions may further include one or moreadditives, including, but not limited to curing agents, matting agents,pigments, fillers, flow control agents, dry flow additives,anti-cratering agents, surfactants, texturing agents, light stabilizers,matting agents, photosensitizers, wetting agents, anti-oxidants,plasticizers, opacifiers, stabilizers, degassing agents, corrosioninhibitors, ceramic microspheres, slip agents, dispersing agents, micapigments, and surface altering additives.

Among various coating composition additives that may be optionallyadded, substances or mixtures of substances added to a polymercomposition to promote or control the curing reaction are curing agents,which include catalyst and hardener. As generally known, curing catalystincreases the rate of a chemical reaction as an initiator. It is addedin a small quantity as compared to the amounts of primary reactants anddoes not become a component part of the chain. Curing hardener, often anamine, enables the formation of a complex three-dimensional molecularstructure by chemical reaction between the polymers and the amine. It isessential that the correct mix ratio is obtained between resin andhardener to ensure that a complete reaction takes place, such that nounreacted resin or hardener will remain within the matrix to affect thefinal properties after cure. Conventional polyamine hardeners compriseprimary or secondary amine groups. A polysilazane-modified polyaminehardener was described in U.S. Pat. No. 6,756,469, providing heatedpolyamine in the presence of a polysilazane to prepare a hardenerimparting enhanced high temperature properties, higher char yields andbetter adhesion properties. In some embodiments, neither catalyst norhardener is needed for a curing process that is initiated via solventcondensation. In some embodiments, each polymer in the composition iscapable of curing independently of the other without the need of formingco-polymers.

The matting agents typically can alter the surface of a coating in sucha way that the light falling on it is scattered in a defined fashion.The matting agent particles stand out from the coating but are invisibleto the human eye. The color of the coating is not affected to any greatextent. Representative examples of such matting agents include inorganicmatting agents such as silica-based ACEMATT® matting agents from EvonikDegussa (Parsippany, N.J.) and silica-based matting agents availablefrom Ineos Silicas (Hampshire, United Kingdom). The matting agents mayvary in size and include materials that are micron sized particles. Forexample, the particles may have an average diameter of from about 0.1 to1000 microns, and in one embodiment from 0.1 to 100 microns.Combinations of matting agents may be used.

The pigments may be of any color or combination of colors, as well asemployed in any pattern or combination of patterns. The pigments usedherein are typically inorganic materials. Inorganic pigments can becrystals of metal oxides. This structure is extremely stable, and setsit apart from organic pigments, which are generally composed of carbon,oxygen, and nitrogen. Such pigments include mixed metal oxides thatinclude more than one type of metal atom along with the oxygen to makethe pigment. In general, pigments are produced by the high temperaturecalcination of high grade metal oxides in a kiln according to given timeand temperature profiles. The resulting mixed metal oxide can be milledusing a variety of high-energy techniques in order to reduce theparticle size. The pigments used herein are typically stable at hightemperatures. Representative examples of such pigments include black andgray inorganic pigments, such as the camouflage inorganic pigmentpackages from Shepherd Color (West Chester, Ohio). The camouflagepigment CM2581 available from Shepherd Color contains a mixture ofchromic oxide (2-8%), copper chromite black spinel (20-30%), titaniumdioxide (50-70%), zinc iron chromate black spinel (10-15%). Combinationsof pigments may be used as needed.

In one exemplary embodiment, a mica pigment is included in thecomposition. Mica pigments are available in a wide variety of colors.Mica pigments have a variety of positive benefits such as, addedcorrosion protection, added thermal insulation values, high temperaturecolor pigmentation, visual enhancement resulted from metallic hues andtones. In one embodiment, the mica pigment is natural or synthetic micagroup minerals. In another embodiment, the mica pigment is natural orsynthetic silica group minerals. In yet another embodiment, thecomposition comprises a mixture of mica group minerals and silica groupminerals. The mica pigment generally comprises between about 1% to about30% (w/w) of the silicon-based coating composition. In some embodiments,the mica pigment comprises about 30%, about 25%, about 20%, about 15%,about 10%, about 5%, or about 1% (w/w) of the total composition.

Other materials may be included in the composition, including but notlimited to flow and leveling agents such as available from BYK (Wesel,Germany), hydrophobic fumed silica such as available from Evonik Degussa(Parsippany, N.J.), alumina fibers and silicon carbide fibers such asavailable from Sigma Aldrich (St. Louis, Mo.), and the like. Ceramicmicrospheres such as available from Zeospheres™ G-600 (Lockport, La.),and the like. Corrosion inhibitor such as available from Halox® 430(Hammond, Ind.), and the like.

In addition, the coating composition additives typically comprise lessthan about 30% of the total silicon-based coating composition. In someembodiments, the additive comprises about 30%, about 25%, about 20%,about 15%, about 10%, about 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.1%, or0% (w/w) of the total composition.

The coating composition may be applied by dipping, spraying, brushing,painting, wiping, immersion, or spin-coating techniques. Theseprocedures will typically provide polymer coatings of thicknesses on theorder of 1 micrometer or even thinner, to up to about 75 microns (ormicrometers, μm) per coat for the cured polymers. If a thicker coatingis desired, multiple coating layers may be provided. The clear coatformulations as provided herein result in a coating transparent andtherefore do not affect the optical appearance of the substrate. Due tothe small coating thickness, only a very small amount of material isrequired, which is advantageous both in terms of cost and alsoecologically, and the weight change of the substrate to be coated isnearly unnoticeable. The coat thickness of the silicon-based coating asprovided herein following evaporation of the solvent and curing is inthe range from about 0.1 to about 50 microns, from about 0.5 to about 40microns, or from about 1 to about 25 microns.

Curing is the process of polymerization after the coating is applied.Curing process can be controlled through temperature, air flow, ratio ofthe solvents, choice of resin and hardener compounds, and the ratio ofsaid compounds. The curing process can take minutes to hours. Someformulations benefit from heating during the cure period, whereas otherssimply require time and ambient temperatures. Coatings may be ambientlycured at room temperature ranging from 5-40° C. By providing slightamount of heat the curing time can be shortened. Curing is performed attemperatures not exceeding about 100° C. These curing atmospheresinclude, but are not limited to, air and other non-reactive or reactivegaseous environments which contain moisture, inert gases like nitrogenand argon, and reactive gases such as ammonia, hydrogen, carbonmonoxide, and so on. Rapid cure times are achieved using this methodwhen the applied coatings are exposed to the moisture-containingatmosphere at room temperature, and the cure can be further acceleratedwith adding heat by using an oven or infrared system.

Coating related testing provides quality control and product descriptionbased on industrial standards. Typical coating tests may include, butnot limited to, thickness test, coefficient of friction test, hardnesstest, scratch resistance test, testing the amount of force needed toscratch the coating from substrate; 90 degree peel from topcoat test; 90degree peel from adhesive test; cross-hatch adhesion test; UV endurancetest; heat stability test; conical bend test, impact direct and indirecttest. In particular, thickness test, measuring the thickness ofsubstrates and top-coated materials, may be carried out using testpanels on which uniform films are produced by a coating suitable forspraying; using micrometers for dried films; using magnetic gauges fornonmagnetic coatings; using Wet Film Thickness Gauge or Pfund Gauge forwet film thickness; or using microscopic observation of precisionangular cuts in the coating film. Hardness test of organic materials maybe carried out using indentation hardness measurements, Sward-typehardness rocker instruments, or pendulum damping testers. In addition,the “kinetic coefficient of friction” (COF, μ), also known as a“frictional coefficient” or “friction coefficient,” describes the ratioof the force of friction between two bodies and the force pressing themtogether. Coefficients of friction range from near zero to greater thanone. Rougher surfaces tend to have higher effective values. The COFmeasured under ASTM D1894 is called Standard COF. More standard ASTM(American Society for Testing and Materials) test methods for coatingsare available at the World Wide Webwernerblank.com/polyur/testmethods/coating_test.htm. In one embodiment,the thickness of the silicon-based coating resulted from thecompositions provided herein is between from about 1 micron to about 45microns. In one embodiment, the hardness of the silicon-based coatingresulted from the compositions provided herein ranges from about 4 H toabout 9 H, using ASTM D3363. Further, in one embodiment, the COF of thesilicon-based coating resulted from the compositions provided herein isbetween from about 0.03 to about 0.04.

Surfaces, substrates and substrate layers suitable for coatingcompositions provided herein may comprise any desirable substantiallysolid material that vary widely. For example, the type of surfaces thatcan be treated with the compositions includes glass; fiberglass; carbonfiber composites; basalt fiber composites; siloxane and ceramic fibers;ceramics, such as, silicon nitride, silicon carbide, silica, alumina,zirconia, and the like; metals, such as, for example, iron, stainlesssteel, galvanized steel, zinc, aluminum, nickel, copper, magnesium andalloys thereof, silver and gold and the like; plastics, such as,polymethyl methacrylate, polyurethane, polycarbonate, polyestersincluding polyethylene terephthalate, polyimides, polyamides, epoxyresins, ABS polymer, polyethylene, polypropylene, polyoxymethylene;porous mineral materials, such as, concrete, clay bricks, marble,basalt, asphalt, loam, terracotta; organic materials, such as wood,leather, parchment, paper and textiles; and coated surfaces, such as,plastics emulsion paints, acrylic coatings, epoxy coatings, melamineresins, polyurethane resins and alkyd coatings. The surface or substratecontemplated herein may also comprise at least two layers of materials.One layer of material, for example, may include glass, metal, ceramic,plastics, wood or composite material. Other layers of materialcomprising the surface or substrate may include layers of polymers,monomers, organic compounds, inorganic compounds, organometalliccompounds, continuous layers and nanoporous layers.

Further, the surfaces and substrates may have different shapes, e.g.,substrates having flat, planar surfaces, molded articles having curvedsurfaces, fibers, fabrics, and the like. It will be appreciated by thoseskilled in the art that the foregoing lists are merely illustrative ofvarious materials which may be coated using the presently disclosedcompositions and methods and are not in any way limiting of thedifferent substrates with which the present disclosure is useful.Insofar as they protect virtually any type of substrate from oxidativethermal degradation, corrosion, or chemical attack. The coatings mayalso be used to strengthen relatively flaw sensitive brittle substratessuch as glass and non-wetting surfaces. The coatings may additionally beuseful to provide bonding or compatibility interfaces between differenttypes of materials.

A particularly advantageous, but non-limiting, use of this coating is asa coating on automobile, aircraft, missiles, aerospace components,marine vessels, wheels, wind generation equipment and blades, engineshrouds, car exhausts, smoke stacks, industrial kilns, combustionchambers, industrial duct and pipe systems, solar panels, electroniccomponents, fire and safety appliance, insulation and energy systems,building surfaces, public spaces, packaging surfaces, outdoor signs andadvertisement billboard or LED screens. Those surfaces are exposed toUV, heat, coldness, moisture, ice build-up, chemical corrosion, and wearand tear from natural physical forces creating friction such as, water,air flow and dust. In addition, such protection is particularly suitablefor mechanical components exposed to high temperatures, including, forexample, exterior aircraft surfaces, a wing slat or pylon made oftitanium, aluminum or cress metal heat shields on an aircraft or othercoated aircraft areas subject to engine efflux. A protective filmprovided by the silicon-based coating compositions disclosed herein overthe base layer of paint or surface material of these surfaces isparticularly useful to protect the surface and the substrate materialfrom various external forces, particularly from the heat and hightemperature, by greatly reducing radiant heat passing through thesurface and the substrate material.

Although the disclosure described herein is susceptible to variousmodifications and alternative iterations, specific embodiments thereofhave been described in greater detail above. It should be understood,however, that the detailed description of the composition is notintended to limit the disclosure to the specific embodiments disclosed.Rather, it should be understood that the disclosure is intended to coverall modifications, equivalents, and alternatives falling within thespirit and scope of the disclosure as defined by the claim language.

DEFINITIONS

As used herein, the terms “about” and “approximately” designate that avalue is within a statistically meaningful range. Such a range can betypically within 20%, more typically still within 10%, and even moretypically within 5% of a given value or range. The allowable variationencompassed by the terms “about” and “approximately” depends on theparticular system under study and can be readily appreciated by one ofordinary skill in the art.

As used herein, the term “w/w” designates the phrase “by weight” and isused to describe the concentration of a particular substance in amixture or solution.

As used herein, the term “ml/kg” designates milliliters of compositionper kilogram of formula weight.

As used herein, the term “cure” or “curing” refers to a change in state,condition, and/or structure in a material that is usually, but notnecessarily, induced by at least one variable, such as time,temperature, moisture, radiation, presence and quantity in such materialof a catalyst or accelerator or the like. The terms cover partial aswell as complete curing

As used herein, the term “hardness” or “H” designates the property of amaterial that enables it to resist plastic deformation, usually bypenetration. However, the term hardness may also refer to resistance tobending, scratching, abrasion or cutting. The usual method to achieve ahardness value is to measure the depth or area of an indentation left byan indenter of a specific shape, with a specific force applied for aspecific time. There are four principal standard test methods forexpressing the relationship between hardness and the size of theimpression, these being Pencil Hardness ASTM D3363, Brinell, Vickers,and Rockwell. For practical and calibration reasons, each of thesemethods is divided into a range of scales, defined by a combination ofapplied load and indenter geometry.

As used herein, the term “coefficient of friction” (COF), also known asa ‘frictional coefficient’ or ‘friction coefficient’ or “kineticcoefficient of friction” and is an empirical measurement which describesthe ratio of the force of friction between two bodies and the forcepressing them together. The coefficient of friction depends on thematerials used. When the coefficient of friction is measured by astandardized surface, the measurement is called “standardizedcoefficient of friction.”

As used herein, the term “corrosion resistant agent” or variationthereof refers to additives in the coating on a surface which inhibitthe corrosion of the surface substrate when it is exposed to air, heat,or corrosive environments for prolonged time periods.

As used herein, the term “monomer” refers to any chemical compound thatis capable of forming a covalent bond with itself or a chemicallydifferent compound in a repetitive manner. The repetitive bond formationbetween monomers may lead to a linear, branched, super-branched, orthree-dimensional product. Furthermore, monomers may themselves compriserepetitive building blocks, and when polymerized the polymers formedfrom such monomers are then termed “block polymers”. Monomers may belongto various chemical classes of molecules including organic,organometallic or inorganic molecules. The molecular weight of monomersmay vary greatly between about 40 Dalton and 20000 Dalton. However,especially when monomers comprise repetitive building blocks, monomersmay have even higher molecular weights. Monomers may also includeadditional reactive groups.

Contemplated polymers may also comprise a wide range of functional orstructural moieties, including aromatic systems, and halogenated groups.Furthermore, appropriate polymers may have many configurations,including a homopolymer, and a heteropolymer. Moreover, alternativepolymers may have various forms, such as linear, branched,super-branched, or three-dimensional. The molecular weight ofcontemplated polymers spans a wide range, typically between 400 Daltonand 400000 Dalton or more.

The following examples are intended to further illustrate and explainthe present disclosure. The disclosure, therefore, should not be limitedto any of the details in these examples.

EXAMPLES Example 1 Preparation of Resin Systems for Making Silicon BasedCoating Compositions

The silicon-based coating formulations provided herein were formed fromtwo or more different resin systems chosen from, what was known asA-Resin, B-Resin, C-Resin, and any combinations thereof. The A-Resin wasmade according to the formulation provided in Table 1. The A-Resin waspurchased from KiON Defense Technologies (Huntingdon Valley, Pa.), andit was sold as KDT HTA 1500 Fast™, an air curable liquid polysiloxazanebased coating resin (8.9 lbs/Gallon).

TABLE 1 A-Resin formulation Ingredient CAS No. Amount (w/w) Appx.Polysilazane >99% (w/w)  Cyclosilazane CAS# 503590-70-3 <5% (w/w)n-Butyl Acetate CAS# 123-86-4 <3% (w/w) (or tert-Butyl Acetate) (CAS#540-88-5)

The B-Resin was made according to the formulation provided in Table 2.The B-Resin was purchased from Genesee Polymers Corp. (Burton, Mich.),and it was sold as Dimethyl Silicone Fluids G-10 products (8.0lbs/Gallon).

TABLE 2 B-Resin formulation Ingredient CAS No. Amount (w/w) Appx.Polydimethylsiloxane Fluid CAS# 63148-62-9  <5% (w/w) Isopropyl AcetateSolvent CAS# 108-24-4 <98% (w/w)

The C-Resin was made according to the formulation provided in Table 3.The C-Resins was purchased from Kadko, Inc. (Beech Grove, Ind.), and itwas sold as a polysilazane based KADKLAD R2X3™ product.

TABLE 3 C-Resin formulation Amount Ingredient CAS No. (w/w) Appx.Polysilane <8% (w/w) Amyl Acetate Blend CAS# 628-63-7 <98% IsopropylAcetate CAS# 108-21-4 25-35% Isoparaffinic Hydrocarbon CAS# 64741-66-850-60% Aliphatic Hydrocarbon CAS# 64742-47-8  5-10% Acetate Ester CAS#108419-34-7 1-5%

The A-, B-, and C-Resin systems were then used in appropriate amount fordifferent clear coat formulations, as such a mix of polysilazane,polysiloxane and/or polysilane and acetate solvent was used to produceformulations of coating products with various desired properties asdescribed below.

Characteristics of the coating products using the formulations providedherein included clear, thin, light, slick, hard, heat resistant, hightemperature resistant, ice build-up resistant, UV resistant, chemicalresistant, and microbial resistant.

Example 2 Thermal Barrier Coat Formulation Part A

A thermal barrier coat silicon-based coating formulation Part A was madeaccording to the formulation provided in Table 4. The Part A compositionof the thermal barrier coat was formed by mixing a number of ingredientsin the amount listed below. The formulation was to be mixed with thermalbarrier coat Part B, resulting a mixture ready to coat a face of a top.

TABLE 4 Thermal Barrier Coat Formulation Part A Composition INGREDIENTAMOUNT (w/w) 1. Base Resin Thurmalox Resin 82% (w/w) 2. SolventIsoparaffin (Isopar ™-G) CAS# 64742-48-9 6% (w/w) tert-Butyl AcetateCAS# 540-88-5 6% (w/w) 3. Additives Ceramic Microspheres 3% (w/w)Corrosion inhibitor 3% (w/w) Total = 100% (w/w)

To blend the ingredients and make 10 gallons of thermal barrier coatformulation Part A, each component was measured out to the appropriatepercentage of the formula needed to create the coating. Each ofingredients was pre-weighed: 82% by formula weight of 10 gallonsThurmalox® Resin (Everett, Mass.), 7% by formula weight of 10 gallonsisoparaffin, 6% by formula weight of 10 gallons tert-butyl acetate, 3%by formula weight of 10 gallons Ceramic Microspheres, such as,Zeospheres® G-600 (Lockport, La.), and 3% by formula weight of 10gallons corrosion inhibitor, such as Halox® 430 (Hammond, Ind.). In thisparticular example, Thurmalox® 270-20 Black was used for the finishedcolor. Isoparaffin was added to adjust drying time of finished formula.The ceramic microspheres were used to accommodate the end use andproperties for a thermal barrier coat.

The thermal barrier coat formulation Part A mixture was first made bymixing Thurmalox® Resin, isoparaffin and the corrosion inhibitor to forma mixture. Each of these components was blended by hand with a stirstick and a high-speed disperser at approximately 8500 rpm forapproximately five (5) minutes, or until the blend was thoroughly anduniformly mixed. The measured amount of ceramic microsphere was thenadded and stirred into the mixture with a stir paddle until a homogenousor uniform blend was formed without breaking or crushing themicrospheres. The stir paddle was rotated at about 500 rpm, and themixing took approximately five (5) minutes. The finished formulated PartA composition was then filtered through a 120-mesh paint filter (U.S.standard sieve size, same below) such that there were no particles ordebris left within the mixture. This filtered Part A composition wasthen placed into a container and sealed tightly to prevent the escape ofsolvents.

Example 3 Thermal Barrier Coat Formulation Part B

A thermal barrier coat silicon-based coating formulation was madeaccording to the formulation provided in Table 5. The base resin mixtureof this particular clear coat was formed by mixing the A-, B- andC-Resins in the amount listed below. The formulation was to be used tocoat the face of a metal surface.

TABLE 5 Thermal Barrier Coat Formulation Part B Composition INGREDIENTAMOUNT (w/w) 1. Base Resin Mixture A-Resin: 66% (w/w) B-Resin: 17% (w/w)C-Resin: 17% (w/w) 2. Solvent tert-Butyl Acetate CAS# 540-88-5 0% (w/w)High-purity Synthetic 0% (w/w) Isoparaffin (Isopar ™-G) 3. AdditivesMatting Agents <2% (w/w) Texturing Agents <2% (w/w) Total = 100% (w/w)

To blend the ingredients and make 10 gallons of thermal barrier coatcomposition Part B, the B-Resin and C-Resin needed to be blendedtogether first. To blend these two resins, the B-Resin and C-Resin wereagitated prior to blending. After agitation, 17% by formula weight of 10gallons B-Resin, 17% by formula weight of 10 gallons C-Resin wereweighed out, and then blended using a mix paddle for a few minutes toobtain a uniform mixture. Since both the B- and C-Resin were very fluidin nature, no extreme agitation was required.

The other ingredient was then weighed out: 66% by formula weight of 10gallons A-Resin. The base resin mixture was made by mixing 66% byformula weight of 10 gallons A-resin with B- and C-Resin blend. When theingredients were mixed into and within one mixture, the mixture wasthoroughly mixed by stir paddle until a homogenous or uniform blend wasformed. The stir paddle was rotated at about 500 rpm, and the mixingtook approximately five (5) minutes. The finished formulated resinsystem was then filtered through a 120-mesh paint filter (U.S. standardsieve size, same below) such that there were no particles or debris leftwithin the coating mixture. This filtered Part B composition was thenplaced into a container and sealed tightly to prevent the escape ofsolvents.

Example 4 Thermal Barrier Coat Formulation MX 490-50%

A thermal barrier silicon-based coating formulation was made accordingto the formulation provided in Table 6. The base resin mixture of thisparticular clear coat was formed by mixing the Part A and Part B resinmixtures in the amount listed below. The formulation was to be used tocoat the face of a painted surface.

TABLE 6 Thermal Barrier Coat Formulation MX 490-50% CompositionINGREDIENT AMOUNT (w/w) Part A: 50% (w/w) Part B: 50% (w/w) Total = 100%(w/w)

To blend the ingredients and make 10 gallons of thermal barrier coat MX490-50% coating composition, the Part A and Part B compositions neededto be blended together first. To blend these two compositions, the PartA composition and Part B composition were agitated prior to blending.After agitation, 50% by formula weight of 10 gallons Part A composition,and 50% by formula weight of 10 gallons Part B composition were weighedout, and then blended using a mix paddle for a few minutes to obtain auniform mixture. The mixing paddle was rotated at about 500 rpm, and themixing took approximately 3-5 minutes.

The finished formulated resin system was then spray coated onto a glasspanel. The coating had a thickness of about 0.5 mil to 1.0 mil (1mil=0.001 inches or 25.4 μm). The theoretical coverage of thisformulation is 1200 sq/ft per gal for a thickness of 1 mil.Pre-conditioning of the substrate surface can be but not limited to dry,clean and contamination free surface.

After application, the coating was allowed to cure ambiently at roomtemperature for 2 hours, it then became dry to touch achievingapproximately 25% of cured film property values. An additional allowanceof 5 days resulted in a finished clear coating with full propertyvalues. With heating temperature up to 350° F., the coating was curedfor about an hour.

The coating was then tested in accordance with ASTM E1530 test standardsfor heat stability resulting in a thermal barrier coating with a heatresistance above 1600° F.; with ASTM D3363 test standards for hardnessresulting in a thermal barrier coating with a hardness of 7 H andhigher; with ASTM D4587-01 test standards for Q-UV resulting in athermal barrier coating exhibiting no visual degradation of surfaceafter 3000 hours of exposure; with ASTM B117-03 test standards for Q-FOGresulting in a thermal barrier coating resistant to any undercutting ofthe coating from the substrate and/or no signs of blistering after 4000hours of exposure; with ASTM D3359-02 test standards for Adhesionresulting in a thermal barrier coating with no visual removal of thecoating at or along the cross hatch scores, resulting a value at 5B.

Example 5 Thermal Barrier Coat Formulation MX 490-10%

A thermal barrier silicon-based coating formulation was made accordingto the formulation provided in Table 7. The base resin mixture of thisparticular clear coat was formed by mixing the Part A and Part B resinmixtures in the amount listed below. The formulation was to be used tocoat the face of a painted surface.

TABLE 7 Thermal Barrier Coat Formulation MX 490-10% CompositionINGREDIENT AMOUNT (w/w) Part A: 10% (w/w) Part B: 90% (w/w) Total = 100%(w/w)

To blend the ingredients and make 10 gallons of thermal barrier coat MX490-10% coating composition, the Part A and Part B compositions neededto be blended together first. To blend these two compositions, the PartA composition and Part B composition were agitated prior to blending.After agitation, 10% by formula weight of 10 gallons Part A composition,and 90% by formula weight of 10 gallons Part B composition were weighedout, and then blended using a mix paddle for a few minutes to obtain auniform mixture. The mixing paddle was rotated at about 500 rpm, and themixing took approximately 3-5 minutes.

The finished formulated resin system was then spray coated onto a glasspanel. The coating had a thickness of about 0.75 mil to 1.0 mil (1mil=0.001 inches or 25.4 μm). The theoretical coverage of thisformulation is 1200 sq/ft per gal for a thickness of 1 mil.Pre-conditioning of the substrate surface can be but not limited to dry,clean and contamination free surface.

After application, the coating was allowed to cure ambiently at roomtemperature for 2 hours, it then became dry to touch achievingapproximately 25% of cured film property values. An additional allowanceof 5 days resulted in a finished clear coating with full propertyvalues. With heating temperature up to 350° F., the coating was curedfor about an hour.

The coating was then tested in accordance with ASTM E1530 test standardsfor heat stability resulting in a thermal barrier coating with a heatresistance above 1600° F.; with ASTM D3363 test standards for hardnessresulting in a thermal barrier coating with a hardness of 5 H andhigher; with ASTM D4587-01 test standards for Q-UV resulting in athermal barrier coating exhibiting no visual degradation of surfaceafter 3000 hours of exposure; with ASTM B117-03 test standards for Q-FOGresulting in a thermal barrier coating resistant to any undercutting ofthe coating from the substrate and/or no signs of blistering after 4000hours of exposure; with ASTM D3359-02 test standards for Adhesionresulting in a thermal barrier coating with no visual removal of thecoating at or along the cross hatch scores, resulting a value at 5B.

Example 6 Thermal Barrier Coat Formulation MX 490-90%

A thermal barrier silicon-based coating formulation was made accordingto the formulation provided in Table 8. The base resin mixture of thisparticular clear coat was formed by mixing the Part A and Part B resinmixtures in the amount listed below. The formulation was to be used tocoat the face of a painted surface.

TABLE 8 Thermal Barrier Coat Formulation MX 490-90% CompositionINGREDIENT AMOUNT (w/w) Part A: 90% (w/w) Part B: 10% (w/w) Total = 100%(w/w)

To blend the ingredients and make 10 gallons of thermal barrier coat MX490-90% coating composition, the Part A and Part B compositions neededto be blended together first. To blend these two compositions, the PartA composition and Part B composition were agitated prior to blending.After agitation, 90% by formula weight of 10 gallons Part A composition,and 10% by formula weight of 10 gallons Part B composition were weighedout, and then blended using a mix paddle for a few minutes to obtain auniform mixture. The mixing paddle was rotated at about 500 rpm, and themixing took approximately 3-5 minutes.

The finished formulated resin system was then spray coated onto a glasspanel. The coating had a thickness of about 0.75 mil to 1.0 mil (1mil=0.001 inches or 25.4 μm). The theoretical coverage of thisformulation is 1200 sq/ft per gal for a thickness of 1 mil.Pre-conditioning of the substrate surface can be but not limited to dry,clean and contamination free surface.

After application, the coating was allowed to cure ambiently at roomtemperature for 2 hours, it then became dry to touch achievingapproximately 25% of cured film property values. An additional allowanceof 5 days resulted in a finished clear coating with full propertyvalues. With heating temperature up to 350° F., the coating was curedfor about an hour.

The coating was then tested in accordance with ASTM E1530 test standardsfor heat stability resulting in a thermal barrier coating with a heatresistance above 1600° F.; with ASTM D3363 test standards for hardnessresulting in a thermal barrier coating with a hardness of 5 H andhigher; with ASTM D4587-01 test standards for Q-UV resulting in athermal barrier coating exhibiting no visual degradation of surfaceafter 3000 hours of exposure; with ASTM B117-03 test standards for Q-FOGresulting in a thermal barrier coating resistant to any undercutting ofthe coating from the substrate and/or no signs of blistering after 4000hours of exposure; with ASTM D3359-02 test standards for Adhesionresulting in a thermal barrier coating with no visual removal of thecoating at or along the cross hatch scores, resulting a value at 5B.

Example 7 Thermal Barrier Coat Formulation MX 6286

A thermal barrier silicon-based coating formulation was made accordingto the formulation provided in Table 9. The base resin mixture of thisparticular clear coat was formed by mixing the Part A, Part B resinmixtures and mica pigments in the amount listed below. The formulationwas to be used to coat the face of a painted surface.

TABLE 9 Thermal Barrier Coat Formulation MX 6286 Composition INGREDIENTAMOUNT (w/w) Mixed Resin Part A: 66.5% (w/w) Part B: 33.5% (w/w) Total =100% (w/w) 70%-99% (w/w) Additives Mica Pigments Silica Group MineralsCAS# 64060-48-6 Mica Group Minerals CAS# 12001-26-2 1-30% (w/w) Total =100% (w/w)

To blend the ingredients and make 10 gallons of thermal barrier coat MX6286 coating composition, the Part A and Part B compositions wereblended together first. To blend these two compositions, the Part Acomposition and Part B composition were agitated prior to blending.After agitation, 66.5% by formula weight of 10 gallons Part Acomposition, and 33.5% by formula weight of 10 gallons Part Bcomposition were weighed out, and then blended using a mix paddle for afew minutes to obtain a uniform mixture. The mixing paddle was rotatedat about 500 rpm, and the mixing took approximately 3-5 minutes. Then90% mixed resin (Part A and Part B in 2:1) by formula weight of10-gallon final finished formula was weighted out. 10% Mica pigment byformula weight of 10-gallon final finished formula, either using thesilica group minerals or mica group minerals, was weighted out and mixedinto the 2:1 Part A and B mixed resin. The mixing paddle was rotated atabout 500 rpm, and the mixing took approximately 3-5 minutes to formuniform final formula of MX 6286.

The finished formulated resin system was then spray coated onto a glasspanel. The coating had a thickness of about 0.75 mil to 1.0 mil (1mil=0.001 inches or 25.4 μm). The theoretical coverage of thisformulation is 1200 sq/ft per gal for a thickness of 1 mil.Pre-conditioning of the substrate surface can be, but not limited to,dry, clean and a contamination free surface.

After application, the coating was allowed to ambient-cure at roomtemperature for 2 hours, it then became dry to touch achievingapproximately 25% of cured film property values. An additional allowanceof 5 days resulted in a finished clear coating with full propertyvalues. With heating temperature up to 350° F., the coating was curedfor about an hour.

The coating was then tested in accordance with ASTM E1530 test standardsfor heat stability resulting in a thermal barrier coating with a heatresistance above 1600° F.; with ASTM D3363 test standards for hardnessresulting in a thermal barrier coating with a hardness of 5-7 H; withASTM D4587-01 test standards for Q-UV resulting in a thermal barriercoating exhibiting no visual degradation of surface after 3000 hours ofexposure; with ASTM B117-03 test standards for Q-FOG resulting in athermal barrier coating resistant to any undercutting of the coatingfrom the substrate and/or no signs of blistering after 4000 hours ofexposure; with ASTM D3359-02 test standards for Adhesion resulting in athermal barrier coating with no visual removal of the coating at oralong the cross hatch scores, resulting a value at 5B. The coatingformed using this formulation have a wide variety of positive benefits,including, but not limited to, corrosion protection, thermal insulation,high temperature color pigmentation, visual enhancement with metallichues and tones.

1. A silicon-based coating composition, comprising: 8% to 30% (w/w ofthe total composition) polysilazane, 8% to 22% (w/w of the totalcomposition) polysiloxane, and 30% to 45% (w/w of the total composition)high temperature silicone-based resin, which composition after curing isa thermal barrier coating that can withstand temperature over 1600° F.in accordance with ASTM E1530 test standards for heat stability, havinga thickness ranging between about 0.4 mil and about 1.5 mil and ahardness ranging between about 4 H and about 9 H.
 2. The silicon-basedcoating composition of claim 1, comprising 10% to 15% (w/w of the totalcomposition) polysilazane.
 3. The silicon-based coating composition ofclaim 1, comprising 10% to 13% (w/w of the total composition)polysiloxane.
 4. The silicon-based coating composition of claim 1,comprising 35% to 40% (w/w of the total composition) high temperaturesilicone-based resin.
 5. The silicon-based coating composition of claim1, further comprising a polysilane.
 6. The silicon-based coatingcomposition of claim 1, further comprising 25% to 45% (w/w of the totalcomposition) an organic solvent chosen from isopropyl acetate,tert-butyl acetate, isoparaffin, and combinations thereof.
 7. Thesilicon-based coating composition of claim 1, further comprising one ormore additives chosen from pigments, matting agents, fillers, flowcontrol agents, dry flow additives, anticratering agents, surfactants,texturing agents, light stabilizers, photosensitizers, wetting agents,anti-static agents, anti-oxidants, plasticizers, opacifiers,stabilizers, degassing agents, corrosion inhibitors, ceramicmicrospheres, slip agents, dispersing agents, mica pigments, and surfacealtering additives.
 8. The silicon-based coating composition of claim 7,wherein the additive comprises ceramic microspheres.
 9. Thesilicon-based coating composition of claim 7, wherein the additivecomprises 1% to about 5% (w/w of the total composition) corrosioninhibitors.
 10. The silicon-based coating composition of claim 1,further comprising from about 1% to about 30% mica pigments chosen frommica group minerals, silica group minerals, and combinations thereof.11. A silicon-based coating composition, comprising: 8% to 30% (w/w ofthe total composition) polysilazane, 8% to 22% (w/w of the totalcomposition) polysiloxane, 35% to 40% (w/w of the total composition)high temperature silicone-based resin, 25% to 45% (w/w of the totalcomposition) an organic solvent chosen from isopropyl acetate,tert-butyl acetate, isoparaffin, and combinations thereof, 1% to about5% (w/w of the total composition) corrosion inhibitors, polysilane, andceramic microspheres, which composition after curing is a thermalbarrier coating composition that can withstand temperature over 1600° F.in accordance with ASTM E1530 test standards for heat stability, havinga thickness ranging between about 0.4 mil and about 1.5 mil and ahardness ranging between about 4 H and about 9 H.
 12. The silicon-basedcoating composition of claim 11, comprising 10% to 15% (w/w of the totalcomposition) polysilazane.
 13. The silicon-based coating composition ofclaim 11, comprising 10% to 13% (w/w of the total composition)polysiloxane.
 14. A method of coating a surface, which method comprises:a. mixing 8% to 30% (w/w of the total composition) polysilazane, 8% to22% (w/w of the total composition) polysiloxane, and 30% to 45% (w/w ofthe total composition) high-temperature silicone-based resin at between500 and 8500 rpm to form a silicon-based coating composition; b. coatingthe silicon-based coating composition onto a surface; and c. curing thecoating ambiently with or without additional heat.
 15. The method ofclaim 14, wherein the composition further comprises a polysilane. 16.The method of claim 14, wherein the composition further comprises 25% to45% (w/w of the total composition) organic solvent chosen from isopropylacetate, tert-butyl acetate, isoparaffin, and combinations thereof. 17.The method of claim 14, wherein the composition further comprisesceramic microspheres.
 18. The method of claim 14, wherein thecomposition further comprises 1% to about 5% (w/w of the totalcomposition) corrosion inhibitors.
 19. The method of claim 14, whereinthe composition further comprises 1% to 30% (w/w of the totalcomposition) mica pigments chosen from mica group minerals, silica groupminerals, any combinations thereof.
 20. The method of claim 14, whereinthe surface is chosen from an aircraft, a missile, a marine vessel, aland vehicle, an equipment, a building, an appliance, a furniture, afloor, and any other exposed surface that reducing friction, protectionfrom dragging, protection from extreme heat, ice build-up and UVdegradation, and/or decreased cleaning and maintenance are desirable.